Production of nanocapsules and microcapsules by layer-wise polyelectrolyte self-assembly

ABSTRACT

The invention relates to capsules coated with a polyelectrolyte shell and methods for the production thereof.

DESCRIPTION

The invention relates to nanocapsules and microcapsules which comprise apolyelectrolyte shell, to a method for the production of these capsules,and to the use thereof.

Microcapsules are known in various embodiments and are used inparticular for controlled release and targeted transport of activepharmaceutical ingredients, and for protecting sensitive activeingredients such as, for example, enzymes and proteins (see, forexample, D. D. Lewis, “Biodegradable Polymers and Drug DeliverySystems”, M. Chasin and R. Langer, editors (Marcel Decker, New York,1990); J. P. McGee et al., J. Control. Release 34 (1995), 77).

Microcapsules can be produced by mechanical-physical processes such as,for example, spraying and subsequent coating. However, the microcapsulesobtainable in this way have a number of disadvantages. In particular, itis not possible with the known mechanical-physical processes to producemicrocapsules with a size of <10 μm (diameter). On the contrary, it ispossible to obtain only microcapsules with relatively large diameters,but the range of applications thereof is restricted because of theirsize. In addition, the known mechanical-physical processes do not resultin a monodisperse capsule distribution but, on the contrary, result in anonuniform distribution of capsules of varying size. This is alsodisadvantageous for many applications in which the size of the capsuleis important.

Besides the mechanical-physical processes, also known for producingmicrocapsules are chemical processes. Thus, it is possible to producemicrocapsules by interfacial polymerization or condensation or bypolymer phase separation from a polymer/solvent mixture (B. Miksa etal., Colloid Polym. Sci. 273 (1995), 47; G. Crotts et al., J. Control.Release 35 (1995), 91; S. L. Regen et al., J. Am. Chem. Soc. 106 (1984),5756). However, the microcapsules produced by known chemical processesalso have a number of disadvantages. In particular, a highpolydispersity, a nonuniform envelope and, frequently, a solidificationof the core are to be observed. Another essential disadvantage of theknown chemical processes derives from the use of organic solvents andpolymerizable organic monomers, which leads to considerable restrictionson the active ingredients which can be used for encapsulation. Inparticular, the use, which is often made necessary thereby, ofwater-immiscible organic liquids as core material drastically limits therange of applications of such microcapsules, particularly in relation toproteins or enzymes.

Lipid liposomes are another system which has been used for encapsulatinginorganic and organic materials (D. D. Lasic, “Liposomes: From Physicsto Applications” (Elsevier, Amsterdam, 1993); S/L. Regen et al., J. Am.Chem. Soc. 106 (1984), 2446). The encapsulation of active ingredients inlipid liposomes makes it possible to produce microcapsules underrelatively mild conditions, which is why liposomes are used as carriersystems for various active pharmaceutical and cosmetic ingredients. Thebiological, chemical and mechanical stability of such liposome capsulesis, however, very low, which limits the general utilizability of suchcapsules. Another disadvantage is represented by the low permeability ofliposome capsules, in particular for polar molecules, which preventsexchange of matter with the surrounding medium.

In another process for producing microcapsules there is initialformation of mixtures of the material to be entrapped and of apolyelectrolyte constituent which can be solidified with, for example,Ca²⁺ ions. This mixture is introduced in the form of very small dropletsinto a Ca²⁺ bath to form a gel structure which can then be surroundedwith a polyelectrolyte capsule in further process steps. A furtherdevelopment of such processes is described in DE 33 06 259 A1, where theuse of Ca²⁺ can be dispensed with. The main disadvantage of theseprocesses is that the lower limit of size of the microcapsules which canbe produced is about 50 μm (diameter), and the wall thickness of theresulting microcapsules is at least 100 nm.

DE-A-40 26 978 describes a process for coating sheet-like supports, witha support being modified so that it has ions or ionizable compounds withthe same charge over the entire area, and one or more layers of organicmaterials which contain in each layer ions of the same charge beingapplied from a solution of such organic materials to the modifiedsupport, where the organic material for the first layer has ions withthe opposite charge to the charge of the ion-modification of thesupport, and in the case of several layers there is alternateapplication of further layers, with ions having the opposite charge tothe previous one in each case, in the same manner as the first layer.The supports disclosed are inorganic or organic support materials havingan even surface. There is no reference to the use of microparticles assupport materials or to a disaggregation of the support materials afterthe coating.

One object of the invention is therefore to provide capsules with asmall diameter in which it is possible to entrap materials such as, forexample, macromolecules, precipitates, liquids or gases. It was furtherintended that the capsules have a high stability and shells which have alow wall thickness and which are permeable in particular to ions andsmall molecules.

The object is achieved according to the invention by capsules having apolyelectrolyte shell and a diameter of up to 10 μm or more.

It has been found, surprisingly, that coating of template particles witha polyelectrolyte shell and, where appropriate, subsequentdisintegration of the template particles make it possible to obtaincapsules with defined inner and outer shell properties and withselectively controllable permeability properties. A polyelectrolyteshell means a shell having a content of polyelectrolytes. Thepolyelectrolyte shell is preferably at least 50%, in particular at least60% and particularly preferably at least 80% composed ofpolyelectrolytes. The capsules according to the invention allow theentrapment also of sensitive molecules under mild conditions, forexample in aqueous solutions. The capsule wall is a polyelectrolyteshell which makes exchange of matter, in respect of low molecular weightsubstances and ions, with the surroundings possible, but, at the sametime, retains macromolecular substances. This separating function of thepolyelectrolyte shell has the effect on the one hand that activeingredients entrapped in the capsule where appropriate are retained, buton the other hand that no interfering macromolecular substances can getinto the capsule from outside. In this way, active ingredients areefficiently protected, even without the addition of preservativesubstances, from biological degradation processes. The chemical andphysical properties of the polyelectrolyte shell serving as capsule wallcan be controlled within wide limits by the structure and composition ofthe shell and the surrounding parameters. Thus, the novel capsules canserve, for example, as transport chambers, in which case the parametersof the outer layer determine transport to preset target sites, forexample in the body.

The novel capsules comprise microcapsules with a diameter of from 1 μmto 50 μm, preferably ≦10 μm, particularly preferably ≦5 μm and mostpreferably ≦2 μm, and nanocapsules with a diameter of ≧10 nm to <1000nm.

The shell of the capsules has a plurality of polyelectrolyte layers.Polyelectrolytes mean in general polymers with groups which are capableof ionic dissociation and may be a constituent or substituent of thepolymer chain. The number of these groups capable of ionic dissociationin polyelectrolytes is normally so large that the polymers arewater-soluble in the dissociated form (also called polyions). In thisconnection, the term polyeletrolytes also means ionomers with which theconcentration of ionic groups is insufficient for water solubility butwhich have sufficient charges to enter into self-assembly. The shellpreferably comprises “true” polyelectrolytes. Depending on the nature ofthe groups capable of dissociation, polyelectrolytes are divided intopolyacids and polybases. On dissociation of polyacids there is formationof polyanions, with elimination of protons, which can be both inorganicand organic polymers. Examples of polyacids are polyphosphoric acid,polyvinylsulfuric acid, polyvinylsulfonic acid, polyvinylphosphonic acidand polyacrylic acid. Examples of the corresponding salts, which arealso referred to as polysalts, are polyphosphate, polysulfate,polysulfonate, polyphosphonate and polyacrylate.

Polybases contain groups able to take up protons, for example byreaction with acids to form salts. Examples of polybases with groupscapable of dissociation located on the chains or laterally arepolyethyleneimine, polyvinylamine and polyvinyl-pyridine. Polybases formpolycations by taking up protons.

Polyelectrolytes suitable according to the invention are bothbiopolymers such as, for example, alginic acid, gum arabic, nucleicacids, pectins, proteins and others, and chemically modified biopolymerssuch as, for example, ionic or ionizable polysaccharides, for examplecarboxymethylcellulose, chitosan and chitosan sulfate, ligninsulfonates,and synthetic polymers such as, for example, polymethacrylic acid,polyvinylsulfonic acid, poly-vinylphosphonic acid and polyethyleneimine.

It is possible to employ linear or branched polyelectrolytes. The use ofbranched polyelectrolytes leads to less compact polyelectrolytemultifilms with a higher degree of porosity of the walls. To increasethe capsule stability it is possible to crosslink polyelectrolytemolecules within or/and between the individual layers, for example bycrosslinking amino groups with aldehydes. A further possibility is toemploy amphiphilic polyelectrolytes, for example amphiphilic block orrandom copolymers with partial polyelectrolyte characteristics to reducethe permeability to small polar molecules. Such amphiphilic copolymersconsist of units differing in functionality, for example acidic or basicunits on the one hand, and hydrophobic units on the other hand, such asstyrenes, dienes or siloxanes etc., which can be arranged as blocks orrandomly distributed over the polymer. It is possible by usingcopolymers which change their structure as a function of the externalconditions to control the permeability or other properties of thecapsule walls in a defined manner. Suitable examples thereof arecopolymers with a poly(N-isopropylacrylamide) content, for examplepoly(N-isopropylacrylamide-acrylic acid), which change their watersolubility as a function of the temperature, via the hydrogen bondingequilibrium, which is associated with swelling.

The release of entrapped active ingredients can be controlled via thedissolution of the capsule walls by using polyelectrolytes which aredegradable under particular conditions, for example photo-, acid-, base-or salt-labile polyelectrolytes. A further possibility for particularpossible applications is to use conducting polyelectrolytes orpolyelectrolytes with optically active groups as capsule components.

It is possible by a suitable choice of the polyelectrolytes to adjustthe properties and composition of the polyelectrolyte shell of the novelcapsules in a defined manner. In the particular case of polyelectrolyteshells built up layer-wise it is possible to vary the composition of theshells within wide limits by the choice of the substances for buildingup the layers. There are in principle no restrictions on thepolyelectrolytes or ionomers to be used as long as the molecules usedhave a sufficiently high charge or/and have the ability to enter into alinkage with the underlying layer via other interactions such as, forexample, hydrogen bonding and/or hydrophobic interactions.

Suitable polyelectrolytes are thus both low molecular weightpolyelectrolytes or polyanions and macromolecular polyelectrolytes, forexample polyelectrolytes of biological origin.

Of particular importance for the use of the capsules is the permeabilityof the shell wall. As already stated above, the large number ofpolyelectrolytes available makes it possible to produce a large numberof shell compositions with different properties. In particular theelectrical charge of the outer shell can be adapted to the purpose ofuse. In addition, the inner shell can be adapted to the activeingredients encapsulated in each case, whereby it is possible toachieve, for example, stabilization of the active ingredient. It is alsopossible in addition to influence the permeability of the shell wallthrough the choice of the polyelectrolytes in the shell and through thewall thickness and the surrounding conditions. This makes it possible todesign the permeability properties selectively and to change theseproperties in a defined manner.

The permeability properties of the shell can be further modified bypores in at least one of the polyelectrolyte layers. Such pores may beformed by the polyelectrolytes themselves if chosen suitably. Besidesthe polyelectrolytes, however, the shell may also comprise othersubstances in order to achieve a desired permeability. Thus, inparticular, the permeability for polar components can be reduced byincorporation of nanoparticles with anionic or/and cationic groups or ofsurface-active substances, such as, for example, surfactants or/andlipids. Incorporation of selective transport systems such as, forexample, carriers or channels into the polyelectrolyte shell, inparticular in lipid layers, makes it possible accurately to adapt thetransverse transport properties of the shell to the particular purposeof use. The pores or channels in the shell wall can be opened or closedspecifically by chemical modification or/and changing the surroundingconditions. Thus, for example, a high salt concentration in thesurrounding medium leads to very high permeability of the shell wall.

A particularly preferred modification of the permeability ofpolyelectrolyte shells can be achieved by depositing lipid layers or/andamphiphilic polyelectrolytes on the polyelectrolyte shell afterdisintegration of the template particles. It is possible in this wayvery greatly to reduce the permeability of the polyelectrolyte shellsfor small and polar molecules. Examples of lipids which can be depositedon the polyelectrolyte shells are lipids which have at least one ionicor ionizable group, for example phospholipids such as, for example,dipalmitoylphosphatidic acid or zwitterionic phospholipids such as, forexample, dipalmitoyl-phosphatidylcholine or else fatty acids orcorresponding long-chain alkylsulfonic acids. It is possible on use ofzwitterionic lipids to deposit lipid multilayers on the polyelectrolyteshell. Further polyelectrolyte layers can then be deposited on the lipidlayers.

The novel capsules preferably have a shell wall thickness from 2 to 1000nm, in particular 2 to 100 nm, for example of from 5 to 8 nm. Thethickness of the shell wall depends on the number of layers of thepolyelectrolyte shell. The capsules preferably contain from 2 to 40,preferably 2 to 20, for example 3 to 10, layers. However, the capsulesmay also contain a larger number of layers, i.e. polyelectrolyte layersand, where appropriate, other layers such as lipid layers.

The novel capsules are further distinguished by their monodispersity.Thus, it is possible to obtain a composition with a capsule distributionin which the proportion of capsules with a deviation of >50% from theaverage diameter is less than 20%, preferably less than 10% and,particularly preferably, less than 1%.

The capsules are very stable to chemical, biological, mechanical andthermal stresses. The capsules can, where appropriate with entrappedactive ingredients, be dried, frozen or/and freeze-dried withoutimpairing their properties. Intact capsules are obtained again afterthawing or resuspension in water.

Drying or freeze-drying of the capsules results in a composition inpowder form which can be resuspended in suitable solvents, in particularin aqueous solutions. The invention therefore further relates to acomposition comprising dried capsules. The drying can be carried out byknown methods, in particular at elevated or reduced temperature or/andreduced pressure.

The invention further relates to a method for the production of capsulescoated with a polyelectrolyte shell, comprising the steps:

-   a) preparing an aqueous dispersion of template particles of suitable    size and-   b) producing a shell around the template particles by application of    polyelectrolytes to the template particles.

Firstly an aqueous dispersion of template particles of suitable size isprepared. The size of the capsules is fixed by the size of the templateparticles. Then preferably a plurality of polyelectrolyte layers isapplied to the template particles to form an enveloped templateparticle. The shape of the shell depends directly on the shape of thetemplate particles.

For the application of the polyelectrolyte layers to the template thereis preferably production of a dispersion of the template particles in anaqueous solution. Polyelectrolyte molecules from which the first layeris to be built up are then added to this dispersion. Thesepolyelectrolyte molecules may have the same or the opposite charge asthe surface of the template particles. The amount of the addedpolyelectrolyte molecules is chosen so that all the material is requiredfor building up the first layer, or an excess is used. In the lattercase, removal of the excess polyelectrolyte molecules not required tobuild up the first layer is expedient before addition of oppositelycharged polyelectrolyte molecules for building up the second layer. Thepolyelectrolyte molecules can be removed by known methods, in particularcentrifugation, filtration or/and dialysis. Removal by membranefiltration as described hereinafter is particularly preferred.Subsequently there is further alternate application of oppositelycharged layers of polyelectrolyte molecules, it being possible to choosefor each layer with the same charge identical or differentpolyelectrolyte species or mixtures of polyelectrolyte species. Thenumber of layers can in principle be chosen as desired. Besidespolyelectrolyte molecules it is also possible to deposit othersubstances such as nanoparticles, surface-active substances or/andlipids on the template particles.

Template particles which can be employed are both inorganic materials,for example metals, ceramics, oxides or salt crystals, and organicmaterials such as polymer latices or melamine-formaldehyde particles,lipid vesicles or biological template particles. Emulsion droplets arelikewise suitable. The size of the template particles can be up to 50μm—especially on use of biological template materials. However, in mostcases, the template particles are up to 10 μm, particularly preferablyfrom 5 nm to 5 μn, in size. The shape of the template particles is notcritical. Both spherical and anisotropic particles can be coated.

It is also possible to employ aggregates of subparticles as initialcores (template particles) for coating with polyelectrolytes. Theseaggregates can, where appropriate, be employed in the preshaped orpreformed state. Such a preforming can be achieved, for example, byapplying external electrical direct or/and alternating fields ormagnetic fields to suspensions with subparticles. The shape of thecapsules can be determined by preshaped aggregates. It is additionallypossible to obtain such aggregates with a great uniformity with regardto the size distribution (monodispersity). However, non-preshapedaggregates are also just as suitable. Spherically shaped aggregates areof particular interest.

The template particles used do not necessarily have to be charged inorder to make self-assembly of polyelectrolyte layers possible. On thecontrary, it is possible to apply to uncharged cores a charged precursorfilm which is bound to the template particles by other interactions, forexample hydrophobic interactions.

After application of the required number of polyelectrolyte layers, theenveloped template particles can, if desired, be disintegrated, inparticular comminuted or disaggregated. This leaves behind “empty”capsules with a polyelectrolyte shell. The disaggregation of thetemplate particles is carried out under conditions in which the shellsremain intact. A disaggregation can take place, for example, thermallyor chemically depending on the material chosen for the templateparticles. The low molecular weight core ingredients produced in thedisaggregation can reach the outside through the pores in the shell.This results in capsules with polyelectrolyte shells which contain an“empty” core. Other coating substances can be applied to the emptypolyelectrolyte molecules.

It is possible after disintegration of the template particles for aliquid phase to be present inside the capsule shell. It is possible inprinciple for the capsules to contain any liquid in their interior, forexample an aqueous liquid, in particular an aqueous salt solution orwater, or else organic solvents, in particular water-immiscible solventssuch as alcohols or hydrocarbons having at least 4 C atoms. The capsulesmay also contain solids or gases in their interior.

It is preferred to employ partially crosslinked melamine-formaldehydeparticles as template particles which can be disaggregated by adjustingthe pH in the medium containing the enveloped particles to an acidicvalue, for example <1.5, while the shell layer itself remains intact.The partially crosslinked melamine-formaldehyde particles can also bedisaggregated by chemical reactions, in particular by sulfonation inaqueous media. The sulfonating agents preferably used are alkali metalsulfates, alkali metal hydrogen sulfites and other water-soluble saltsof sulfurous acid. Other examples of template particles which can bedisaggregated are soluble polymer cores, for example urea-formaldehydeparticles, or salt crystals.

It is additionally possible to use as template materials, for example,cells, for example eukaryotic cells such as, for example, mammalianerythrocytes or plant cells, single-celled organisms such as, forexample, yeasts, bacterial cells such as, for example, E. coli cells,cell aggregates, subcellular particles such as, for example, cellularorganelles, pollen, membrane preparations or cell nuclei, virusparticles and aggregates of biomolecules, for example protein aggregatessuch as, for example, immune complexes, condensed nucleic acids,ligand-receptor complexes etc. The method according to the invention isalso suitable for encapsulating living biological cells and organisms.Likewise suitable as templates are aggregates of amphiphilic materials,in particular membrane structures such as, for example, vesicles, forexample liposomes or micelles, and other lipid aggregates.

The disintegration of biological template particles can take place byadding lytic reagents. Lytic reagents suitable for this purpose arethose able to disaggregate biological materials such as proteins or/andlipids. The lytic reagents preferably comprise a deproteinizing agent,for example peroxo compounds such as, for example, H₂ 0 ₂ or/andhypochlorite compounds such as, for example, sodium or potassiumhypochlorite. Surprisingly, disintegration of the template particlestakes place within a short incubation time, for example 1 min to 1 h, atroom temperature. The disintegration of the template particles issubstantially complete because no residues of the particles aredetectable even on examination of the remaining shells under theelectron microscope. It is also possible on incorporation of biologicalpolyelectrolytes into the shell for empty layers to be produced withinthe polyelectrolyte shell.

The fragments formed on disintegration of the template particles, forexample in the case of partially crosslinked melamine-formaldehydeparticles the oligomers produced on disaggregation, can escape from theinterior of the capsules to the outside through pores, in particularnanopores, in the shell wall. They can then, if required, be removedfrom the capsules. This removal can be carried out by methods known tothe skilled worker, for example by dialysis, filtration or/andcentrifugation. However, removal of template particle fragments is oftenunnecessary. The capsule can be used even without a removal step.

It is also possible with the novel method to produce capsules withentrapped active ingredients or capsules for entrapping activeingredients. Loading of the interior with small molecules can take placeby varying the permeability of the shell as a function of the externalphysical and chemical parameters. A state of high permeability is set upfor the loading. The entrapped material is then retained by altering theexternal parameters or/and closing the pores, for example bycondensation of the shell or chemical modification of the pores orchannels.

The active ingredients may be both inorganic and organic substances.Examples of such active ingredients are catalysts, in particularenzymes, nanoparticles, active pharmaceutical ingredients, polymers,dyes such as, for example, fluorescent compounds, sensor molecules, i.e.molecules which react detectably to a change in surrounding conditions(temperature, pH), crop protection agents and aroma substances. Sincethe capsules may comprise aqueous solutions in their core, it ispossible for even sensitive molecules to be entrapped under mildconditions.

On entrapment of catalysts, for example ceramic and/or metallicparticles or enzymes, in the capsules it is possible for the catalystseither to be adsorbed on the inside of the capsule wall or to be presentas free molecules in the capsule interior, so that a virtually loss-freeuse of the catalysts is made possible. The catalyst-containing capsulescan be retained or recovered more easily than the free catalyst.Contamination of the catalysts is substantially precluded by theprotecting and separating function of the capsule shell relative to thesurrounding medium. In particular, the permeability properties of thecapsule walls prevent catalysts entrapped inside the capsules havingtheir activity blocked or inhibited by macromolecular substances, whileentry of substrate and exit of products is possible.

The capsules may also comprise entrapped active pharmaceuticalingredients. In this case, the capsule acts in particular as transportvehicle in order to stabilize the active pharmaceutical ingredients,protect them from degradation or/and transport them to the required siteof action in the body. Specific transport can be achieved by selectionof the surface properties of the outer shell.

The polyelectrolyte shell of the capsules is preferably permeable forlow molecular weight substances but prevents macromolecules from passingthrough. The shell wall thus represents a barrier to microorganisms andexternal digestive enzymes secreted by them. It is therefore possiblefor biodegradable substances to be entrapped in the novel capsuleswithout preservatives being necessary for stabilization.

The capsules can also be used as reaction chambers for chemicalreactions or as precipitation or crystallization templates, in whichcase it is possible to employ empty capsules or capsules comprising anactive ingredient or catalyst. Because of the fact that the permeabilityof the capsule walls can be controlled so that, for example, they allowlow molecular weight substances to pass through but substantially retainmacromolecules, the high molecular weight products produced in achemical reaction, for example polymers produced in a polymerization,can be retained in the interior in a simple way during the synthesis.The reaction product synthesized at the same time in the external mediumcan be removed, subsequently or even during the reaction, for example bycentrifugation or/and filtration.

The supply of the reaction substrate can be controlled during thereaction by the diffusion through the capsule walls. New ways ofintervening in the progress of reactions emerge from this. The externalmedium can be replaced, for example continuously by filtration or forexample also suddenly by centrifugation, the polymerization reaction canbe stopped as desired by removing the substrate or the monomer can bereplaced. It is thus possible to produce defined copolymers ormultipolymers in a novel way. Since the progress of the reaction can becontrolled by the monomer supply through the permeation, it is possibleto produce in the capsules products with novel and different molecularweight distributions, for example highly monodisperse products. Polymerssynthesized inside capsules can be detected, for example, by NMR, by IR,spectroscopically by titration with fluorescent dyes and by confocalmicroscopy. The gain in mass and thus the kinetics of the reaction canbe followed by single particle light scattering.

On use of anisotropic capsules for packaging active ingredients or asreaction chambers, for example for syntheses or precipitation processes,and, where appropriate, subsequent disaggregation of the templateshells, it is possible to produce particle compositions as dispersionswith predetermined shapes and forms. The invention thus also relates toanisotropic particle compositions which are obtainable by encapsulatingactive ingredients in a polyelectrolyte shell, for example by synthesisor precipitation and subsequent removal of the template, for example bythermal or chemical treatment. These anisotropic particles preferablyhave the shape of the structures used as template. Anisotropic particlescan be moved, for example rotated or aligned, by applying fields. It ispossible in this way to produce dispersions with switching properties.

A further possibility is to use the capsules for introducing organicliquids such as, for example, alcohols or hydrocarbons, for examplehexanol, octanol, octane or decane, or for encapsulating gases. Suchcapsules filled with an organic, water-immiscible liquid can also beemployed for chemical reactions, for example polymerization reactions.The monomer can thus be specifically concentrated in the interior of thecapsules through its distribution equilibrium. It is possible whereappropriate for the monomer solution to be encapsulated in the interioreven before the start of the synthesis.

However, it is also possible to encapsulate active ingredients which areunable, because of their size, to penetrate through the polyelectrolyteshell. For this purpose, the active ingredient to be entrapped iscoupled to or immobilized on the template particle or is encapsulated ortaken up by the template particle, for example by phagocytosis orendocytosis in the case of living cells or by encapsulation ofnanoparticles in soluble template materials. After disintegration of thetemplate particles, the active ingredient is released inside thepolyelectrolyte shell. It is expedient to choose the conditions fordisintegration of the template particle in this case so that no unwanteddecomposition of the active ingredient takes place.

Coupling of the active ingredient to the template can take placedirectly, but can also be brought about by a linkage mediator. Thelinkage mediators preferably used are molecules which can be degraded orbroken down under particular conditions. Polylactic acid is particularlypreferably used as linkage mediator. For this purpose, the activeingredient is immobilized on the template particle, for example apartially crosslinked melamine-formaldehyde particle, by means of thelinkage mediator, in particular polylactic acid. In this way the activeingredient to be entrapped itself becomes a constituent of the layerstructure in the coating of the core. After disaggregation of thetemplate particles and, where appropriate, degradation of the linkagemolecules, the active ingredient is released inside the shell. It ispossible with this method to entrap any active ingredients in the shell,in particular nanoparticles and nonbiological macromolecular componentsand, preferably, biological macromolecules such as, for example,proteins, in particular enzymes.

A further possibility is to immobilize cationic polymers or particles inthe shell for example with 4-pyrenesulfonate (4-PS). These particles arethen released inside the shell by dissolving out 4-PS in salt solutions.

However, incorporation of active ingredients in the interior surroundedby the shells can also be carried out by previous introduction of theactive ingredients into the template particles on use of reversiblemicrogels as template particles. Thus, for example, the use of partiallycrosslinked methylol-melamine cores before the coating makes it possibleto incorporate in swollen cores substances which are entrapped in thecore after a reversible shrinkage.

The capsules can also be immobilized on a surface. Adjustment of thecharge on the outer layer and the free functionalizability of theexternal shell makes immobilization of the capsules which is independentof the condition of the entrapped molecules possible. This opens upnumerous possible applications, especially in the area of sensor systemsand surface analysis. This may entail the polyelectrolyte-coatedtemplate particles adhering to a surface, and the template particlesthen being dissolved out of the previously immobilized coated cores inorder to form immobilized capsules. However, it is equally possible forthe dissolving of the cores to take place before deposition on thesurface.

The capsules can be employed in numerous areas of application, forexample sensor systems, surface analysis, as emulsion carriers,microreaction chambers such as, for example, for catalytic processes,polymerization, precipitation or crystallization processes, in pharmacyand medicine, for example for targeting active ingredients or asultrasonic contrast agents, in food technology, cosmetics,biotechnology, information technology, the printing industry(encapsulation of dyes), photographic industry and for veterinarymedicine or agriculture (active ingredients for animal health, activeingredients for agriculture or horticulture). The capsules can furtherbe employed for building up microcomposites or nanocomposites, i.e.materials consisting of at least two different materials and having amicroscopic or nanoscopic arrangement.

On use of the capsules as reaction chambers it is possible for the lowmolecular weight substances such as, for example, precursors andproducts to permeate through the shell walls, whereas the catalysts, forexample, are entrapped. On use of microcapsules or nanocapsules loadedwith catalysts, the capsules being packed, for example, in a column,considerably more catalyst is available for the reaction than withconventional surface-bound catalysts, because the size of the surface islimiting there. It is a particular advantage that the catalyst insidethe capsule does not have to be removed again from the production byelaborate methods. In addition, the useful life of the catalysts isimproved because macromolecular substances, in particular bacteria andfungi, cannot get through the shell walls. This reduces the highsterility demands placed on many processes, which opens up manyindustrially simple applications of biological catalysts.

Sensor molecules can also be entrapped in the capsules. These may beenzymes which, in the presence of a substrate, form products which canbe detected optically or in another way, for example colored orfluorescent products, under suitable conditions. However, it is alsopossible to entrap electrically active sensor molecules, in particularoxidizable or reducible substances, in which case the capsules can beimmobilized on electrodes. In this case, a particular advantage besidesthe protective function of the capsules is that the sensor molecule doesnot come into direct contact with the electrode.

The capsules can also be used for producing crystals or amorphousprecipitates of organic or inorganic materials or for entrapping organicor inorganic crystals or amorphous precipitates. The capsules arepreferably used as crystallization or precipitation chamber or templatesfor producing in particular monodisperse crystals or precipitates. Ahigh degree of monodispersity can be obtained with the novel capsulesbecause the maximum size of the entrapped particles is limited by thesize of the capsules. Chemical groups on the inner shell wall can beused as crystallization nuclei. For this purpose, molecules having sidechains which favor crystal growth are used in the innermost layer in thelayer-wise building up of the shell of the capsules. Thus, for example,it is possible to attach polyphosphates to the inside of the shell inorder to form CaCo₃ in the interior. It is beneficial to usepolyelectrolytes which suppress crystal growth, for example amines, asoutermost layer of the polyelectrolyte shell of the capsules.

The capsules can also be used to build up microcomposites ornanocomposites. Microcomposites and nanocomposites are materialsconsisting of at least two different materials and having a microscopicor nanoscopic arrangement. Such composites often imitate productspresent in nature, such as, for example, mussel shells which, asnanocomposites, consist of ordinary lime and protein molecules. Suchcomposites have surprisingly great strength while being of low weight.

Ordered macroscopic structures can be built up by the assembling.

Anisotropic shells produced using anisotropic template particles, forexample biological template particles, allow, in conjunction with, forexample, crystallization or/and precipitation, composites withanisotropic properties to be produced. Thus, for example, magneticellipsoids can be produced for example by packing with magneticparticles or/and by adsorption of magnetic nanoparticles to thepoly-electrolyte shell. These anisotropic particles show an orientationin the magnetic field, which makes it possible to change the opticalproperties of a particle suspension rapidly (magneto-optical switch). Ananalogous process is possible with ferroelectric particles. It ispossible with the aid of these particles, for example, to stimulatesmall paddle wheels to pump with a rotating field (micromechanics). Itis also possible to heat anisotropic particles by dissipation. This canbe used to produce extremely localized heat sources which can be movedwith electrical or with magnetic fields. This makes it possible toproduce local hyperthermia effects. A further possibility is to produce,by ordered alignment of anisotropic particles, composite materials witha hierarchic structure and interesting macroscopic physical anisotropicproperties.

As previously stated, the permeability of the polyelectrolyte shell canbe controlled by modifications, for example application of lipid layers.This can be utilized for pharmaceutical applications by applying lipidsto the shell after the encapsulation of polar low molecular weightsubstances, in order in this way to reduce the permeability of the shellfor the encapsulated substances. The encapsulated substance is then ableto escape only slowly through the lipid layer at a rate which isconstant over a long period, which is often desirable forpharmacological administrations.

It is possible by the encapsulation and subsequent disaggregation oftemplates to produce accurate three-dimensional impressions of templateparticles. Block crosslinking of the polyelectrolyte shells results inmesoporous materials with a monodisperse accurate pore distribution.These materials have a large internal surface area together with greatstrength, which make them excellent filter substances for industrialpurposes. Mesoporous materials with predetermined pores can be producedby selection of the templates (shape and size).

It is, of course, possible by varying the materials used to produce thepolyelectrolyte shells also to vary the surface chemistry within widelimits.

Finally, the polyelectrolyte shells can also be used to produce pHgradients between the interior of the shell and the volume surroundingthe shell. This pH gradient can in turn be utilized for efficientloading of the shells with active ingredients.

Yet a further aspect of the invention is the application of a pluralityof successive layers to a carrier by a filtration method. This methodmakes it possible to produce, in a simple manner and on a large scale,capsules coated with polyelectrolyte molecules. Surprisingly, evensensitive template particles such as biological cells can be coated by afiltration method.

The invention thus relates to a method for application of a plurality oflayers of coating substances to template particles, comprising thesteps:

-   (a) contacting the template particle with a first coating substance    in a fluid, preferably aqueous reaction medium in a reaction chamber    which is limited on at least one side by a filtration membrane,    under conditions with which a layer of the first coating substance    is formed on the template particle,-   (b) draining at least part of the reaction medium with, where    appropriate, excess first coating substance present therein through    the filtration membrane into a filtrate chamber, there preferably    being essentially complete draining of the excess first coating    substance,-   (c) contacting the template particle with a second coating substance    in a fluid reaction medium in a reaction chamber which is limited on    at least one side by a filtration membrane, under conditions with    which a layer of the second coating substance is formed on the    template particle,-   (d) draining at least part of the reaction medium with, where    appropriate, excess second coating substance present therein through    the filtration membrane into a filtrate chamber, there preferably    being essentially complete draining of the excess second coating    substance, and-   (e) where appropriate repeating steps (a) and (b) or/and (c) and (d)    a plurality of times.

The first and second coating substances preferably used arepolyelectrolyte species, or mixtures of polyelectrolyte species, ofopposite charge in each case. It is also possible to use nanoparticles,amphiphilic polyelectrolytes, lipids or/and surfactants as coatingsubstances.

The template particles are preferably selected from particles having adiameter of up to 50 μm, in particular up to 10 μm. Particles capable ofdisaggregation as previously mentioned, for example partiallycrosslinked melamine-formaldehyde particles, biological particles oraggregates of biological or/and amphiphilic materials, in particularbiological aggregates such as cells, cell aggregates, virus particlesetc., are preferably used.

In order to make complete removal of excess coating substance possibleafter a coating step, a washing medium, for example water or an aqueousbuffer solution, is introduced into the reaction chamber during or/andafter step (b) or/and (d). Addition of the washing medium takes place,especially with sensitive template particles such as biologicalaggregates, in such a way that the volume of the medium present in thereaction chamber is controlled in accordance with a preset program, forexample remains essentially constant in step (b) or/and step (d).

Steps (a) and (c) can each be carried out in the same reaction chamberbut also in different reaction chambers. The filtration membranes areexpediently chosen so that, on the one hand, they are able to retainparticulate template materials but, on the other hand, they make rapidremoval of the used reaction medium possible. Examples of suitablefilter materials are polyamide, cellulose nitrate and cellulose acetate.In order to avoid aggregation or/and blockage of the filter withsensitive template particles, the method is carried out under conditionswhich suppress adhesion of template particles. Thus, it is possiblewhere appropriate to use for each filtration step membranes which havethe same charge as the polyelectrolyte species used in the particularstep.

The filtration can be expedited by applying a positive pressure in thereaction chamber or/and a vacuum in the filtrate chamber. With sensitivetemplate particles, in particular biological aggregates, the filtrationis essentially carried out without a pressure difference (pressuredifference ≦±0.5 bar) between reaction chamber and filtrate chamber. Inaddition, stirring of the reaction chamber is in many casesadvantageous, at least during steps (a) or/and (c), in particularcontinuous stirring throughout the process.

The novel membrane filtration method can be carried out continuously,allows relatively large amounts of coated particles to be produced in avery short time, can be monitored visually and very substantiallyprevents aggregation of particles. The method can be carried out on anindustrial scale and can, by reason of its flexibility, be adapted todifferent demands of the specific particles and coating systems. On useof soluble template particles it is possible for the cores to be brokendown continuously subsequent to the coating.

The invention is explained further by the appended figures and examples.

FIG. 1 represents a diagrammatic illustration of a preferred embodimentof the novel method.

FIG. 2 shows the layer thickness as a function of the number of layerson absorption of poly(allylamine hydrochloride) (PAH) andpoly(styrenesulfonate, sodium salt) (PSS) onto negatively chargedpolystyrene (PS) latex particles.

FIG. 3 shows an SEM image (scanning electron microscopy) of apolyelectrolyte shell with nine layers [(PSS/PAH)₄/PSS] afterdisaggregation of the core. The outer layer is PSS.

FIG. 4 shows a TEM image (transmission electron microscopy) of apolyelectrolyte shell with nine layers [(PSS/PAH)₄/PSS].

FIG. 5 shows atomic force micrographs of PSS/PAH polyelectrolyte shells.The number of polyelectrolyte shells is 3 [PSS/PAH/PSS] in FIG. 5(A) and9 [(PSS/PAH)₄/PSS] in FIG. 5(B).

FIG. 6 shows an AFM image of PS latex particles with a diameter of 1.28μm and a polyelectrolyte shell with six layers (PAH/PSS)₃. The outerlayer is PSS.

FIG. 7 shows normalized light-scattering intensity distributions ofPAH/PSS-coated PS latex particles. Particles with 11 and 21 layers arecompared with the uncoated particles.

FIG. 8 shows a TEM image of a PS latex particle coated with four PAH/PSSlayers and then three pairs of layers each consisting of one magnetitelayer and one PSS layer. The scale corresponds to 200 nm.

FIG. 9 shows an AFM image of a polyelectrolyte shell produced by coatinga 3.7 μm MF latex particle with 10 PSS/PAH layers and thendisaggregating the template particle.

FIG. 10 shows an AFM image of polyelectrolyte shells obtained by coatingglutaraldehyde-fixed human erythrocytes with ten PSS/PAH layers and thendisaggregating the template particle. The scale values on the axes arein μm and the values of the height scale are in nm.

FIG. 11 shows an AFM image of polyelectrolyte shells obtained by coating3.7 μm MF latex particles with ten chitosan/chitosan sulfate layers andthen disaggregating the template particle.

FIG. 12 shows a CLSM image of chitosan/chitosan sulfate microcapsulesconsisting of eleven layers, where FITC-labeled PAH was used asoutermost layer.

FIG. 13 shows the zeta potential of uncoated and chitosan/chitosansulfate-coated 3.7 μm MF latex particles.

FIG. 14 shows the fluorescence intensity of a suspension, containing6-CF as fluorescent marker, of polyelectrolyte shells in relation to thepH of the surrounding medium, which was titrated by HCl or H-PSS withthe molecular weight stated in each case.

FIG. 15 shows the relation between the pH inside the capsules and the pHof the surrounding medium, titrated with H-PSS (MW 4200) in the absenceof salt (black circles) and in the presence of 1 mM NaCl (whitecircles). The broken line shows the control obtained by titration of thecapsule dispersion with HCl.

EXAMPLES Example 1

Production of Partially Crosslinked Melamine-formaldehyde TemplateParticles

Monodisperse melamine-formaldehyde polymer particles can be produced bya polycondensation reaction from melamine-formaldehyde precondensates inthe range of size up to 15 μm (cf. DD 224 602). The size of theparticles can be influenced by the monomer condensation, the pH, thereaction temperature and the addition of surfactant. Methods describedin the prior art result in highly crosslinked particles which areinsoluble in most organic solvents such as, for example, xylene, tolueneand alcohol, and in acids and bases. Partially crosslinkedmelamine-formaldehyde template particles which can be disaggregated areproduced by modifying the method described in the prior art by stoppingthe polycondensation process at a particular initial stage of thereaction. This results in cores which are soluble in aqueous media. Thereaction can be stopped by rapidly lowering the temperature, by changingthe pH into the alkaline range and by choosing suitable precondensates,in particular tetramethylolmelamine.

The cores obtained in this way can be disaggregated in aqueous media byaddition of acid and/or by particular chemical reactions, in particularsulfonation. The sulfonating agents which can be employed are, inparticular, alkali metal sulfites, alkali metal hydrogen sulfites andother water-soluble salts of sulfurous acid. The ability of the cores tobe disaggregated can be influenced by the timing of the stoppage of thepolycondensation process. The stoppage is carried out 1 min to 3 h afterthe start of the reaction, depending on the reaction conditions anddepending on the required ability of the cores to disaggregate. The rateof disaggregation can further be controlled by the choice of pH,temperature and sulfonation reagent. It is thus possible to obtain coreswith a rate of disaggregation of from 0.1 s to 10 h, once againdepending on the disaggregation conditions. These melamine-formaldehydeparticles capable of disaggregation are referred to herein as partiallycrosslinked melamine-formaldehyde particles.

Example 2

Production of Empty Polyelectrolyte Shells Using Melamine-formaldehydeParticles as Template

2.1

Polyelectrolytes are applied stepwise from diluted aqueous solutions tomonodisperse, colloidal, partially crosslinked melamine-formaldehydeparticles (MF) which have been produced as described in Example 1 andhave a diameter of 2.0 or 3.3 μm (cf. FIG. 1). The polyelectrolytelayers are applied by alternate adsorption of oppositely chargedpolyions, starting with the adsorption of a negatively charged polyanion(for example polystyrene sulfonate, sodium salt; PSS) onto thepositively charged MF particles. Typical adsorption conditions were 20mM polyelectrolyte (stated concentration based on monomer), 0.5M NaClwith particle concentrations of 0.5% by weight. The adsorption time was20 min. The MF particles had a density of 1.5 g/cm³.

After completion of this adsorption cycle, excess electrolyte wasremoved by repeated centrifugation/washing cycles. For this purpose, thecoated cores were sedimented at a centrifugation speed of 2000 rpm (byusing an Eppendorf rotor). Then three washing steps were carried outwith deionized water before adding the next polyelectrolyte in order toensure complete removal of unadsorbed polyelectrolyte. The requirednumber of polyelectrolyte layers can be applied by repetition of thisprocedure.

The pH was then reduced to <1.6, by which means the MF cores aredisaggregated within a few seconds. The fragments penetrate through thepores in the shell to the outside and can be removed, so that an emptypolyelectrolyte shell is obtained. There is no detectable disaggregationof the cores at pH values above 1.8.

2.2

100 μl of a 3% strength dispersion of partially crosslinkedmelamine-formaldehyde particles with a particle size of 3 μm are mixedwith 400 μl of a solution of 20 mM mono PSS in 0.5M NaCl. After anaction time of 5 min with gentle shaking, 1 ml of pure water is added.After centrifugation at 2000 rpm, the supernatant is decanted, thesediment is made up with pure water and the centrifugation is repeated.A further decantation and another centrifugation cycle afford purifiedMF particles covered with a PSS layer. A poly(allylamine hydrochloride)layer (PAH) is subsequently applied in an analogous manner. These cyclesare repeated alternately depending on the required number of layers. Thecentrifugation cycle when the building up of the last layer is completeis followed by addition of 1 ml of a 0.1N hydrochloric acid. Shaking forabout 5 min results in a clear solution because the turbidity of thesolution caused by the particles has disappeared. This is followed bycentrifugation at 10,000 rpm for about 10 min. During thiscentrifugation a fine sediment which has a slightly milky appearance andcontains the formed polyelectrolyte shells separates out. Even gentleshaking after addition of water is sufficient to resuspend the shells.Two further centrifugation steps result in a purified 3% strengthdispersion of spherical, monodisperse polyelectrolyte shells in water. Asample of these shells can be examined by scanning electron microscopy,transmission electron microscopy and/or atomic force microscopy.

2.3

1.59 mg of Na polystyrene sulfonate (PSS) are added to a dispersion ofpartially crosslinked melamine-formaldehyde particles in 0.5M NaCl. TheMF dispersion contains a total of 2.2×10⁸ particles. After gentleshaking for 20 minutes, 0.81 mg of polyallylamine hydrochloride isadded. After a further 20 min, 1.59 mg of PSS are added with gentleshaking. This procedure is repeated 5× with one PAH addition and one PSSaddition each time. This results in melamine-formaldehyde particlescovered with 13 alternating layers. The pH is reduced by addition of 10ml of 1N hydrochloric acid so that the MF cores disaggregate. Thepolyelectrolyte shells are separated from the supernatant bycentrifugation at 15,000 g for 15 min.

Example 3

Characterization of the Polyelectrolyte Shells

3.1 Dependence of the Layer Thickness on the Number of Layers

Layers of poly(allylamine hydrochloride) (PAH) and poly(styrenesulfonate, sodium salt) (PSS) were adsorbed alternately onto negativelycharged polystyrene (PS) latex particles. The layer thickness wasmeasured by single particle light scattering. The increase in intensityof the scattered light is a measure of the amount adsorbed and wasconverted into the layer thickness using the refractive index of thepolyelectrolyte layers. The insert in FIG. 2 indicates the zetapotential, derived from electrophoretic mobility measurements (MalvernZetasizer 4), for the adsorption of PAH and PSS onto polystyreneparticles (black circles) and for the adsorption of PSS and PAH ontopositively charged MF particles (white circles).

The zeta potential is a measure of the effective charge density on theparticle surface. As is evident from FIG. 2, the surface potential isreversed with the adsorption of each polyelectrolyte layer onto thepolystyrene or MF particles. A reversal of the surface potentoial favorsthe subsequent adsorption of the oppositely charged polyion.

Investigations by time-of-flight mass spectrometry have shown that ondisaggregation of the partially crosslinked MF template particles at apH <1.6 there is formation of MF oligomers which consist mainly of 5-10units of tetramethylolmelamine. These MF oligomers have a characteristiccross-sectional dimension of about 1 nm, as determined by moleculardynamic simulations (using the DISCOVERY program). These oligomers areejected from the core and permeate through polyelectrolyte layers whichform the shell, and can finally be removed from the empty shells bycentrifugation. This confirms that the shells are readily permeable bymolecules with a size in the region of a few nm, in particular ≦10 nm,preferably ≦5 nm.

3.2 Scanning Electron Microscopic Investigations of the PolyelectrolyteShells

The polyelectrolyte shells were investigated by scanning electronmicroscopy (SEM). Firstly an MF core with a diameter of 3.3 μm wascoated with 9 polyelectrolyte shells [(PSS/PAH)₄/PSS]. The outermostlayer is PSS. After disaggregation of the MF core, the resultingcapsules were investigated by SEM. As is evident from FIG. 3, thediameters are in the region of 4.0±0.5 μm. The shells are immobilized bya strong electrostatic attraction to the positively chargedpoly(ethyleneimine)-coated glass surface. In addition, a certain degreeof drying of the capsules occurs during the investigation. This leads tothe shell becoming wrinkled. However, as is evident from FIG. 3, noholes or traces of fissures are to be found in the shells.

The SEM measurements were carried out using a Zeiss DSM40 instrumentwhich was operated with an accelerating voltage of 15 KeV. The sampleswere produced by applying a drop of a solution containing the shells topoly(ethyleneimine)-coated glass. After the shells had settled on theglass supports they were thoroughly rinsed with water and cautiouslydried under a stream of nitrogen.

3.3 Transmission Electron Microscopy (TEM)

Nine polyelectrolyte [(PSS/PAH)4/PSS] layers were applied to MF templateparticles with a diameter of 2 μm. The template particles were thendisaggregated. The samples were fixed with glutaraldehyde, OsO₄ andK₂Cr₂O₇, dehydrated in ethanol/acetone, embedded in an Epon 812/AralditeM resin and polymerized in an oven for two days. Thin sections (80 to100 nm) were prepared using a Reichert ultratome and stained with uranylacetate and lead citrate. The measurements were carried out in a JEOL100 B electron microscope.

As is evident from FIG. 4, the stained polyelectrolyte layer surroundingthe more lightly stained interior of the cell can be clearly identified.The homogeneous shape of the shells shows that the produced capsulesretain both the diameter and the spherical shape of the templateparticles provided the inner aqueous solution is not removed. It isfurther evident that the thickness of the polyelectrolyte shellconsisting of nine layers is of the order of 20 nm. This value agreeswith the data shown in FIG. 2 for polyelectrolyte-coated polystyreneparticles. It can be concluded from this that the nature of the templateparticles has a negligible effect on the thickness of thepolyelectrolyte layers. It is also evident from the TEM image that thepolyelectrolyte shells have neither fissures nor holes.

3.4 Atomic Force Microscopic (AFM) Investigations

PSS/PAH polyelectrolyte shells were produced as described above using MFtemplate particles with a diameter of 3.3 μm. The number ofpolyelectrolyte layers was 3 [PSS/PAH/PSS] (FIG. 5(A)) or 9[(PSS/PAH)₄/PSS] (FIG. 5(B)). These capsules were investigated by AFM inthe tapping mode (TM). FIG. 5 shows that the three-dimensionalpolyelectrolyte shells are continuous films having wrinkles which resultfrom evaporation of the aqueous interior. As can be seen, the height ofthe capsules increases as the number of layers increases. The maximumheight of the dried shells in Figure A is of the order of 50 nm and inFIG. 5(B) is of the order of 100 nm.

Example 4

Production of Polyelectrolyte Shells Immobilized on a Support

A carefully cleaned glass support is immersed in an aqueous solution of0.5 mg/ml of poly-ethyleneimine for 5 min. The glass support is thenblown dry under a stream of nitrogen. 100 μl of a 3% strength dispersionof partially crosslinked melamine-formaldehyde particles with a particlesize of 1 μm diameter are mixed with 400 μl of a 20 mM mono Napoly(styrenesulfonate) solution in NaCl. After shaking gently for 5 min,1 ml of pure water is added. After centrifugation at 2000 rpm, thesupernatant is decanted, the sediment is made up with pure water, andthe centrifugation is repeated. A further decantation and anothercentrifugation cycle result in MF particles covered with a PSS layer.Then 400 μl of a 20 mono mM polydiallyldimethylammonium chloridesolution in 0.5M NaCl are added to the particles and incubated for 20min. This procedure is repeated a second time. The particles are thenagain coated with PSS as described above and centrifuged three times.The sediment is redispersed in 0.5 ml of pure water and applied to theglass support. After 5 min, the glass support is immersed in a 0.1Nhydrochloric acid solution for 5 min. The glass plate is then immersedthree times in pure water, without drying in between, for 5 min eachtime. The glass plate is then dried under a gentle stream of nitrogen.The result obtained is tightly packed polyelectrolyte shells immobilizedon a polyethyleneimine-coated glass support and consisting of 5 layers.

Example 5

Entrapment of Active Ingredients in Polyelectrolyte Shells

100 μl of a 2% strength dispersion of partially crosslinkedmelamine-formaldehyde particles with a particle size of 0.9 μm diameterare mixed with 400 μl of a 0.5M NaCl solution, pH 6, containing 0.5mg/ml polylactic acid. After shaking gently for 5 min, 1 ml of water isadded. After centrifugation at 2000 rpm, rotor radius 5 cm, thesupernatant is decanted, water is replenished and the centrifugation isrepeated. A further decantation and another centrifugation cycle resultin melamine particles covered with a polylactic acid layer. These aremixed with 0.4 ml of a 1 mg/ml lysozyme solution at pH 6.0 and incubatedfor 20 min, shaking gently. This is followed by washing three times inwater. Another polylactic acid layer is applied as described above at pH6. A poly(allylamine hydrochloride) layer (PAH) is then applied,followed by further layers in the sequence PSS/PAH/PSS.

The particles are then transferred into a 0.1N hydrochloric acidsolution. After a few seconds, lysozyme-filled polyelectrolyte shellsare formed by disaggregation of the cores and the two polylactic acidlayers. These shells are centrifuged in pure water at 15,000 g twice.The supernatant is discarded each time. The resulting sediment comprisesconcentrated capsules filled with lysozyme, a protein, and having apolyelectrolyte shell of 4 layers. Other biological macromolecules canbe encapsulated in a similar way.

Example 6

Production of Empty Polyelectrolyte Shells Using Biological Particles asTemplate

Bovine or human erythrocytes are fixed with glutaraldehyde in aconcentration of 2%. After an action time of 60 min at 200° C., thesolution is removed by centrifugation and the erythrocytes are washedfour times in double-distilled water. The fixed erythrocytes are thenmade up with unbuffered 154 mM NaCl solution.

For the coating, 4 ml of solution with a concentration of 0.5 g/dl PAHand 0.5M NaCl are made up with an erythrocyte concentration of about2.5% (v/v). After an action of 10 min at 200° C., the erythrocytes areremoved by centrifugation and washed twice in a 154 mM NaCl solution.Then 4 ml of solution with a concentration of 0.5 g/dl PSS and 0.5M NaCland an erythrocyte concentration of about 2.5% (v/v) are made up. Afteran action time of 10 min at 200° C., the erythrocytes are removed bycentrifugation and washed twice in a 154 mM NaCl solution. Theapplication of PAH and PSS layers can be repeated as often as desired.

The template can be disaggregated in a 1.2% strength NaOCl solution.Commercially available deproteinizing agents (Medical Instruments) ordrain cleaners (for example Chlorix) are equally suitable. The actiontime is about 20 min at 20° C. and can be checked visually by thedisappearance of the turbidity of the solution. The remaining polymershells are then washed in NaCl solution.

It is also possible to coat E. coli or yeast cells in an analogous way.Unfixed cells can also be coated.

Example 7

Deposition of Lipid Layers onto Poly-electrolyte Shells

Two different methods were used to deposit lipid layers onpolyelectrolyte shells.

7.1

200 μl of a suspension of polyelectrolyte shells are resuspended byrepeated washing in methanol. After the third wash, 500 μl of a lipidsolution of, for example, 1 mg/ml dipalmitoylphosphatidic acid (DPPA) ordipalmitoylphospatidylcholine (DPPC) in methanol are added to thesediment in place of pure methanol. The shells are resuspended in thismethanolic lipid solution, and the suspension is kept at a temperatureof 90° C. in a water bath. The evaporating methanol is replaced bydropwise addition of water in 20 μl portions. Replacement of 700 μl ofmethanol by water takes about 30 min.

After completion of the evaporation, the suspension of shells is washedthree times with water and repeatedly centrifuged. The lipid-coatedshells can be sedimented by centrifugation at 25,000 rpm for 20 min.

7.2

Dispersions of DPPA or 90% DPPC and 10% DPPA with a concentration of 1mg of lipid/ml in water are prepared by ultrasound treatment. 500 μl ofthe resulting dispersion of lipid vesicles are added to 200 μl of aconcentrated suspension of shells. After 30 min, the samples arecentrifuged at 25,000 rpm for 20 min. The supernatant is discarded andreplaced by water. This procedure is repeated three times. The result isa concentrated suspension of lipid-coated shells.

Example 8

Entrapment of Organic Solvents in Polyelectrolyte Shells

An aqueous suspension of polyelectrolyte shells is centrifuged at 3000rpm for 5 min. Removal of the supernatant is followed by addition ofmethanol. The shells are resuspended and centrifuged at 4000 rpm for 10min. The supernatant is again removed, methanol is added and the sampleis centrifuged under the same conditions as before. This procedure isrepeated three times. After the last centrifugation with methanol, thesupernatant is replaced by hexanol. The shells are resuspended andcentrifuged at 5000 rpm for 10 min. This procedure is repeated threetimes again.

A similar procedure is used to entrap octanol, octane or decane in theshells, using as starting material the shells present in a hexanolsolution. The centrifugation speed is increased to 7000 rpm (10 min) foroctanol and octane and to 7500 rpm (10 min) for decane.

The resulting sediment is finally resuspended in water. The shellsremain in the aqueous phase, while the traces of solvent still presentin the sediment form a second organic phase between the shells. By usingfluorescent markers for the organic and the aqueous phase it is possibleto show by confocal microscopy that the shells are filled with organicsolvent.

The described procedure makes it possible to produce a very stableemulsion of nonpolar liquids in water. The monodispersity of theoriginal shells results in the emulsion produced likewise beingmonodisperse. Another advantage is that even the shape of the individualdroplets can be controlled—depending on the template used. This makes itpossible to produce emulsions with surface area:volume ratios differentfrom those of a sphere.

Example 9

Precipitation and Crystallization in Polyelectrolyte Shells

The empty polyelectrolyte shells can also be used for controlledprecipitation or crystallization of organic or inorganic materials. Forthis purpose, polyelectrolyte shells are incubated in a 30 mM6-carboxyfluorescein (6-CF) solution at pH 7. The pH of the solution isthen rapidly changed to a value of 3.5, at which 6-CF is substantiallyinsoluble. Incubation for 1 to 12 h results in a mixture of completely6-CF-filled and empty shells. It was possible in further experiments toprecipitate rhodamine B in polyelectrolyte shells by increasing the pH.

The precipitation of active ingredients can also be induced by othermeasures, for example solvent replacement, salt precipitation etc. Theseresults show that the polyelectrolyte shells can be used as templatesfor crystallization or precipitation processes, making it possible tocontrol the size and shape of colloidal particles resulting from thereaction.

Example 10

Polymerization in Polyelectrolyte Shells

A 3% solution of diallyldimethylammonium chloride (DADMAC) is mixed in a2% strength suspension of polyelectrolyte shells with the polymerizationinitiator sodium peroxodisulfate (30 mg/100 ml) and polymerized at 70°C. for 9.5 h. The polymer PDADMAC synthesized in the volume phase isremoved by centrifugation. The presence of polymer adsorbed to thenegatively charged capsule walls and polymer present inside the capsulecan be detected by treatment with 100 mM 6-CF, which binds to the aminogroups of PDADMAC.

Polyelectrolyte shells consisting of 9 layers ([PSS/PAH]₄PSS) aredeposited on human erythrocytes, and the template particles are removed.A further PAH layer is then applied. The capsules are used forfree-radical polymerization of acrylic acid to polyacrylic acid. Forthis purpose, a 3% strength monomer solution is mixed in a 2% strengthcapsule suspension with the initiator sodium peroxodisulfate (30 mg/100ml) and polymerized at 70° C. for 9.5 h. The polyacrylic acidsynthesized in the volume phase is removed by centrifugation. Thepresence of polyacrylic acid adsorbed onto the negatively chargedcapsule walls, but also inside the capsules, can be detected afteraddition of 100 mM rhodamine B, which binds selectively to anionicgroups. The adsorption of acrylic acid to capsule walls can be preventedby using capsules with an external negative charge.

Example 11

Colloidal Stabilization of Poly-electrolyte Shells Filled with OrganicSolvents

Polyelectrolyte shells in aqueous solution are loaded with DPPA (withaddition of 5% labeled DPPC). The aqueous dispersion is mixed withpentanol, octanol or decane. The samples are centrifuged at 17,000 rpmfor 2 min. The mixture separates into two phases, with the shells beinglocated at the layer between the aqueous and the organic phase. Theaqueous phase is extracted and the sample is washed three times with theorganic solvent.

It can be demonstrated by confocal microscopy that the lipids remain onthe shells even after contact with the organic solvent and that anaqueous phase is encapsulated inside the shell. For this purpose, beforeapplication of the lipid layer, the capsules are incubated in a 0.1 mM6-CF solution for 1 h and, after application of the lipids, the sampleis washed four times with water to remove excess lipids and 6-CF. Aconfocal image recorded 12 h after the preparation shows that theaqueous 6-CF solution is still encapsulated inside the shells. Theorganic solvent shows no fluorescence.

These results show that the polyelectrolyte shells can be used forencapsulating organic solvents in water and, conversely, also forencapsulating an aqueous phase in an organic medium. It is thus possibleto produce stable oil-in-water and water-in-oil emulsions without usingsurface-active agents.

Example 12

Production of Polyelectrolyte Shells by Membrane Filtration

12.1 Materials

The template particles used were charged polystyrene latex particleswith a diameter of 640 nm, which were produced by the method of Furosawaet al. (Colloid-Z. Z. Polym. 250 (1972), 908), partially crosslinkedmelamine-formaldehyde particles with diameters of 3.7 μm and 5 μm, andglutaraldehyde-fixed human erythrocytes. The coating substances used aresodium poly(styrenesulfonate) PSS (MW 70,000), poly(allylaminehydrochloride) PAH (MW 8000 to 11,000), poly(diallyldimethylammoniumchloride) PADMAC (MW 100,000), chitosan (MW 200,000 to 300,000),chitosan sulfate (MW 200,000 to 300,000) and magnetite particles. Forthis purpose, aqueous solutions of 1 or 2 mg/ml PSS, PAH or PDADMAC in0.5M NaCl are prepared. Chitosan sulfate is prepared as solution with aconcentration of 1 mg/ml in 0.5M NaCl. Chitosan is dissolved at aconcentration of 1 mg/ml in 0.5M NaCl with addition of 0.3% (v/v) aceticacid.

An SM 16692 vacuum pump (Sartorius AG, Gottingen, Germany) is used forthe membrane filtration, with which it is possible to produce a vacuumof about 100 mbar and a positive pressure of up to 3 bar. An SM 16510polycarbonate filtration unit (Sartorius) is used for the vacuumfiltration, and an SM 16526 unit (Sartorius) is used for the pressurefiltration.

Membrane filters with a diameter of 47 mm of the following types areused: Sartolon polyamide SM 25007-047 N (0.2 μm), Sartolon polyamide SM25006-047 N (0.45 μm), cellulose acetate SM 11104-047 N (0.8 μm) andcellulose nitrate SM 11306-100 N (0.45 m).

12.2 Methods

Polystyrene and melamine-formaldehyde latex suspensions are employed ata concentration of from 1 to 30% (v/v). The concentration of theerythrocyte suspension should not exceed about 10% (v/v). The volume ofthe particle suspensions used in the first adsorption step is between 10ml and 50 ml. The adsorption time is always 5 min. The particles arethen washed with water.

The membrane filtration can be carried out as vacuum filtration,pressure filtration and filtration without change of pressure. It ispreferable during the polyelectrolyte adsorption to apply a slightreduction in pressure in the incubation chamber relative to the lowerfiltrate chamber in order to avoid loss of the incubation medium and thepolyelectrolyte during the adsorption.

One aspect in the selection of the membrane filter is the sign of thecharge on the polyelectrolyte to be adsorbed. Polyamide filters, forexample, are suitable in the case of polycations (PAH, chitosan).Cellulose acetate or celluose nitrate filters can be used in the case ofpolyanions. It is possible in this way to minimize blockage of thefilter by polyelectrolyte adsorption.

It is expedient to carry out the filtration under conditions with whichformation or compaction of the filter cake is avoided or restricted.Adhesion of PS and MF latex particles with an outer layer of PSS or PAHto the filter surfaces, as well as the tendency to aggregation or/andflocculation thereof, is slight. Filtration is therefore possible up tohigh particle concentrations (20%) without interruption or replacementof the filtered suspension medium by the washing medium. In the case oferythrocytes, care is needed during the deposition of the first four orfive layers in order to prevent aggregation. The concentration of thesuspension should therefore not exceed about 5 to 10% (v/v), and theformation of a filter cake should be avoided as far as possible. Aftercompletion of the initial adsorption cycles there is a decrease in thetendency to aggregation and in the tendency to adhere to the filter. Anyflocculation occurring during the addition of a polyelectrolyte can beredissolved or broken up during the course of the process by adding anoppositely charged poly-electrolyte, for example the followingpolyelectrolyte, without damaging the product.

Similar results are obtained with the chitosan/chitosan sulfate system.Substantially complete suppression of aggregation can be achieved bystirring.

12.3 Results

FIG. 6 shows an AFM image of PS latex surfaces after application of 3PAH/PSS pairs of layers. The surfaces are smooth and no polyelectrolyteaggregates are evident. These particles were produced by vacuum membranefiltration with a suction pressure of about 100 mbar and with use of 450nm cellulose nitrate membrane filters. It is likewise possible to usepolyamide filters or alternately negatively charged celluose acetate andpositively charged polyamide filters.

In FIG. 7 there is determination of the growth of the thickness of theshells on the surface of 640 nm PSS latex particles by single particlelight scattering by the method described by Lichtenfeld et al. (ColloidSurfaces A 104 (1995), 313). The scattered light intensity increaseswith the particle size. The results for particles with 11 and 21 PAH/PSSlayers are shown, compared with uncoated particles.

The TEM image of a with a mixed layers of polyelectrolyte and magnetiteparticles which were produced by precipitation of iron(II) and iron(III)salts in ammonium hydroxide solution and stabilization by HCl (Massartand Cabuil, J. D. Chemie Physique 84 (1987), 967) is shown in FIG. 8.Firstly two PAH/PSS bilayers are adsorbed. Then three magnetite/PSSbilayers are adsorbed. The filtrate solution was in each case colorlessand clear. This denotes complete adsorption of the magnetite. Magnetiteaggregates formed on the surface are clearly evident.

On use of MF particles capable of disaggregation as template the resultsof the membrane filtration are likewise good. Microcapsules with 10PAH/PSS layers of 3.7 μm MF particles are shown in the AFM image in FIG.9. The template particles were disaggregated in citrate buffer pH 1.4.The morphology of the flat shell is clearly evident.

FIG. 10 shows an AFM image of PAH/PSS microcapsules with 10 layersdeposited on the surface of glutaraldehyde-fixed human erythrocytes.Despite the negative charge of the cells it is beneficial to start witha PSS adsorption layer. It is possible in this way to reduce the extentof aggregation during the first adsorption steps. The filtration shouldtake place under mild pressure conditions (only slight or no elevationor reduction in pressure) in order to avoid the formation of filtercakes. Similar precautionary measures are necessary on use of PDADMAC aspolycation. Excellent results are obtained under conditions withoutpressure even in such sensitive systems.

FIGS. 11 to 13 show results obtained on use of chitosan/chitosan sulfateas polyelectrolyte pair. FIG. 11 is an AFM image of MF particlesprovided with 10 layers after disaggregation of the core. In order tofacilitate investigation of the shell morphology, FITC-labeled PAH wasapplied as eleventh layer and the shell was investigated by confocallaser scanning microscopy. The result is shown in FIG. 12. FIG. 13indicates the zeta potentials of layer-wise growing microcapsules. Oddnumbers for layers correspond to chitosan sulfate and are characterizedby negative zeta potentials. Even-numbered layers correspond to chitosanand show positive zeta potentials.

Example 13

Permeability of Polyelectrolyte Shells

Polyelectrolyte shells were produced by coating 3 μmmelamine-formaldehyde particles using sodium poly(styrenesulfonate) witha molecular weight of 70,000 and poly(allylamine hydrochloride) with amolecular weight of 50,000. A PAH labeled with fluoresceinisothiocyanate (FITC-PAH) is employed for the confocal fluorescencemicroscopy (Sukhorukov, Colloids Surfaces A 137 (1998), 253).

Suspensions of melamine-formaldehyde particles with a diameter of 3 μmare coated with 13 PAH and PSS layers. The core is then disaggregated byincubation in 0.1M NaCl for 5 min.

The permeability of the polyelectrolyte microcapsules is investigated byconfocal microscopy. For this purpose, initially a solution of PAH-FITC(molecular weight 50,000) is mixed with the shells to give a finalconcentration of 0.5 mg/ml. The permeability of the shell walls for highmolecular weight PAH-FITC is so low that no fluorescence was detectableinside the capsules after incubation for 20 min. In contrast to this,6-carboxyfluorescein (6-CF) is able easily to penetrate through thewalls of the shells.

FIG. 14 shows the fluorescence intensity of a suspension ofpolyelectrolyte capsules containing 6-CF as fluorescent marker inrelation to the pH in the surrounding medium titrated with polystyrenesulfonic acid and HCl. The results show that polystyrene sulfonic acidin the respective molecular weights used (70,000-4200) was unable topenetrate through the olyelectrolyte shells.

FIG. 15 shows the pH inside the capsules as a function of the volume pHtitrated with H-PSS (molecular weight 4200) in the absence of salt andin the presence of 1 mM NaCl. It is evident that no significantdiffusion of PSS polyanions with the respective molecular weights testedinto the interior of the capsule takes place at least within one hour.This leads to the development of a pH gradient between the interior ofthe capsule and the volume. The pH in the interior is about 1 pH morebasic than the pH of the volume. This applies in particular when thevolume pH is less than 5.5.

1-50. (canceled)
 51. A method comprising applying a plurality of layersof coating substances to template particles by: (a) contacting thetemplate particles with a first coating substance in a fluid reactionmedium in a reaction chamber which is limited on at least one side by afiltration membrane, under conditions with which a layer of the firstcoating substance is formed on the template particles; (b) draining atleast part of the reaction medium with, where appropriate, excess firstcoating substance present therein through the filtration membrane into afiltrate chamber; (c) contacting the template particles with a secondcoating substance in a fluid reaction medium in a reaction chamber whichis limited on at least one side by a filtration membrane, underconditions with which a layer of the second coating substance is formedon the template particles; (d) draining at least part of the reactionmedium with, where appropriate, excess second coating substance presenttherein through the filtration membrane into a filtrate chamber; and (e)optionally repeating steps (a) and (b) or steps (c) and (d) a pluralityof times.
 52. A method according to claim 51, wherein the first andsecond coating substances are selected from the group consisting ofoppositely charged polyelectrolyte species or mixtures ofpolyelectrolyte species.
 53. A method according claim 51, wherein thetemplate particles have a diameter of up to 50 μm.
 54. A methodaccording to claim 51, wherein the template particles are soluble andthe disaggregation of the cores is carried out after completion of thecoating process.
 55. A method according to claim 53, wherein thetemplate particles are selected from biological particles or aggregates.56. A method according to claim 51, wherein a washing medium is addedduring or after step (b) or step (d).
 57. A method according to claim56, wherein the addition of the washing medium takes place so that thevolume of the medium remains essentially constant in step (b) or step(d).
 58. A method according to claim 51, wherein the filtration iscarried out essentially without a pressure difference between reactionchamber and filtrate chamber.
 59. A method according to claim 51,wherein the reaction chamber is stirred at least during step (a) or (c).60. A method according to claim 59, wherein the reaction chamber isstirred throughout the process.